Simulation Modeling of the Hall Electromagnetic Transducer for Measuring the Thickness of a Ferromagnetic Film

Abstract

This paper presents a comprehensive study of 3D magnetic field modeling for a Hall effect-based electromagnetic transducer designed for high-precision, non-contact measurement of ferromagnetic film thickness. The transducer features a solenoidal coil and a sensitive gold Hall plate, with the test material placed between them. Magnetic field interaction with the material causes measurable changes in Hall voltage, correlating with layer thickness. A simulation model was developed in ANSYS Maxwell to visualize magnetic field distribution and study its dependence on geometry, material properties, and sensor positioning. Simulations with and without the specimen allowed analysis of system sensitivity and resolution, leading to the identification of optimal design parameters. The study demonstrates improved measurement accuracy for coating thicknesses from 1 to 400 um. Additionally, it underscores the importance of computational methods in the development, optimization, and validation of electromagnetic measurement systems. The integration of simulation tools enhances predictive capability and reduces reliance on costly experimental testing, making the approach valuable for industrial applications requiring precise, real-time thickness control.